Visor with fixed pattern curve

ABSTRACT

The present invention is to provide a cap visor, once the visor is bent, a fixed pattern curve can be kept constant unless an outer force is applied thereto. Visor formed with a fixed pattern curve will not restore to the original shape automatically. For assuming a fixed pattern given by the bent visor is composed of a multiaxial warp knit fabric (MWK)  11  clad in a cloth  12,  for example, each of a plurality of warps  11   a  is extended across and downward each of a plurality of wefts  11   b  to form a MWK  11.  For example, the warp  11   a  is flexibly bent to form a fixed pattern curve; the weft  11   b  is allowed pliably and toughly extendable relative to the warp  11   a.  The warp is made of high density polyethylene (HDPE) filament thread, the weft is made of nylon filament thread.

FIELD OF THE INVENTION

The present invention is related to a cap, particularly to a visor made of multiaxial warp knit fabric, which is composed of each high density polyethylene filament threads is extended across and downward each nylon filament threads respectively, clad in cloth materials; after bending, a fixed pattern curve of the visor can be kept constant in the ensemble.

BACKGROUND OF THE INVENTION

A cap, if commercially available, usually is adorned with a visor constructed by a flexible plastic sheet clad in a cloth material. Such a visor may be temporarily folded to an extent suitable for holding to hand, but when wearing, it could not be shaped in a fixed pattern curve as desired. On the contrary, the visor soon restores to its original pattern curve. Therefore, a visor no longer feasible for the transition from an old shape to a new shape causes a user felt a cap visor for some new tastes has nothing unusual to experience.

Those skilled in the art have provided a visor assumed fixed patterns curve whenever being bended. Such as US application serial no. 2006/014793 assigned to Sung Yie Liao and earlier published on Jul. 6, 2006 entitled “Visor cap or hat having foldable bill” wherein the visor portion includes an outer covering, and an inner flexible sheet member engaged in the outer covering and made of high density polyethylene, to allow the visor portion to be folded to and retained in various contours. The outer covering is preferably made of cloth materials. The high density poly ethylene for making said flexible sheet member includes a melting point ranged between 110-140° C., and includes a density ranged between 0.950 and 0.97 g/cm³, and includes a consistency no less than 99.8%.

Since a whole piece of visor made of valuable HDPE will cost more capital expenditure than the conventional plastic sheet; moreover, a whole piece of HDPE may lead to a hardness of the visor higher than expected. On the other hand, a flexibility of the visor decreased results in a user hard to fold and then receive it into a container, further to wash it cleanly.

A whole piece of HDPE is also a plastic sheet without any capillary action can be expected thereon, in other words, the HDPE is impervious to air and liquid.

Based on the assumption as discussed above, providing an inexpensive and breathable visor with flexibility, after bending, a fixed pattern curve can be kept constant in the ensemble shall be an objective of the present invention.

SUMMARY OF THE INVENTION

Accordingly, the present invention a visor with fixed pattern curve can be realized by each high density polyethylene (HDPE) filament threads is extended across and downward each nylon filament threads respectively to form a multiaxial warp knit fabric (MWK) clad in cloth materials. Such a visor 1 combined with a crown 2 to form a cap, characterized in that: the visor 1 consists of a cloth 12 wrapped up a multiaxial warp knit fabric 11, which is formed by each of HDPE filament threads as warps 11 a is extended across and downward each of nylon filament threads as wefts 11 b respectively, each HDPE warp is flexibly easy to bend with a fixed pattern, each nylon weft is pliably and toughly extendable, thereby a plurality of previous orifices formed among a plurality of nylon wefts 11 b and a plurality of HDPE warps 11 a respectively.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1: shows a schematic view of the visor of the present invention.

FIG. 2: shows a sectional view indicated by numerals 2-2 of FIG. 1.

FIG. 3: shows a perspective view of the first embodiment of the present invention.

FIG. 4: shows a plan view of the first embodiment of the present invention.

FIG. 5: shows a sectional view indicated by numerals 5-5 of FIG. 4.

FIG. 6: shows a sectional view indicated by numerals 6-6 of FIG. 4.

FIG. 7: shows a cross sectional view of a periphery enclosed by both sides of the visor of the first embodiment of the present invention.

FIG. 8: shows a schematic view of the on the rim of the multiaxial warp knit fabric (MWK) is further clad in a layer of cloth material.

FIG. 9: shows a sectional view in accordance with 9-9 of FIG. 8.

FIG. 10: shows a schematic view of the visor of the present invention in use.

FIG. 11: shows a schematic view of a visor in use followed the action of FIG. 10.

FIG. 12: shows a schematic view of a visor in use followed the action in FIG. 11.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The description is described according to the appended description hereinafter.

As shown in FIG. 1, a schematic view of the visor of the first embodiment of the present invention is illustrated. A cap 10 includes a visor 1 and a crown 2, and the visor 1 is combined to the crown 2 by stitching integrally to form a cap 10. Said visor 1 includes a multiaxial warp knit fabric (MWK) 11 clad in a cloth 12. A cross sectional view of the visor is illustrated in FIG. 2 as indicated by numerals 2-2 in FIG. 1.

As shown in FIG. 3, a perspective view of the flexibly MWK is illustrated. Each of a plurality of wefts 11 b is extended across and downward each of a plurality of warps 11 a, the warp is a filament thread flexibly easy to bend with a fixed pattern, the weft is a pliably and toughly extendable filament thread.

Said cloth 12 can be divided into a top layer and a bottom layer made of conventional cloth, cloth-nylon, cloth of synthetic fibers and so on. A MWK is introduced between the top and bottom layers.

Said warp flexibly easy to bend with fixed pattern curve is made of high density polyethylene (HDPE) filament thread, which can be heated under melt point up to 110° C. for a duration 30 minutes repeatedly to maintain a deformed shape as a new pattern curve basis, furthermore, the warp is neither inducing chemical erosion nor mixing in compound-solvent, due to short and long-term plasticity exhibited by nylon, HDPE filament threads (as known, PE is characteristic of “soft chain” of carbon bonds passed through gel spinning having ultimate strength up to 372 g/den and crystal modulus up to 2719 g/den is superior to other polymers), threads made of HDPE with high crystallinity about 95% at a density of 0.97 g/cm³ (PE with a crystallinity 60%, density of 0.915 g/cm³), HDPE filament thread is thus flexibly easy to bend with a fixed pattern curve. Thereby, a memory plastic effect in the range about 20˜180 degrees is likely occurred to the bendable HDPE filament thread. In other words, the thread easy to bend will not restore to the original shape automatically, unless an outer force is applied to deform the shape as a new pattern curve is bestowed thereupon once more. HDPE filament thread is commercially available, such as Spectra 90, 100 of DSM Co., Dutch, or Toyobo Co., Japan etc. While the nylon filament thread can be formed with a 38% fiber hollow ratio, thereby to increase the softness of the nylon, such as commercially available Microart fiber of Unitika Co. Japan. Particularly as only the specific gravity of HDPE is a little less than water, it may be suitable for a more lightweight nylon to crosscut to form textile in use.

Said pliably and toughly extendable thread relative to the HDPE must be made of nylon, for the reason when “cross but not link” to form the MWK through a knitter. One thread must be drawn therein first and then to accommodate the other thread is extended across and downward thereof. For example, a weft 11 b is first drawn therein for being extended across a warp 11 a thereto. Due to a haul at the weft 11 b; therefore, a latch needle is benefited from such a pliably and toughly extendable thread (i.e. weft) to draw an HDPE thread to crosscut the weft 11 b. Furthermore, a thread made of nylon, after bending, is also deformed with a modified pattern curve. But the modified pattern curve of nylon, of which the maintainability is little by little deconcentrated from the bended portion to about 50˜60 degree alone. Since an elasticity of HDPE thread is less strength than the nylon, therefore, the bended HDPE thread is easy to keep fixed pattern curve than the nylon. The whole MWK can keep a fixed pattern curve in the ensemble due to the cross but not link HDPE cooperated with the nylon filament threads to support a fixed pattern curve mainly due to the HDPE filament threads as warps predominate over the extendable nylon wefts.

According to the embodiments as discussed above, a warp 11 a of the present invention though make from HDPE filament thread, a proper diameter of the warp 11 a should be in the range of 0.8˜1.8 mm, wherein a preferable diameter is 1.1˜1.5 mm. While a weft 11 b is made of nylon, a proper diameter is in the range of 0.4˜1.2 mm, a preferable diameter is 0.6˜0.8 mm. As mentioned above, a diameter of the HDPE is larger than the nylon. Where when the diameter of the HDPE, or nylon is larger than 1.8 mm, or 1.2 mm respectively, the flexible effect of the MWK 11 may be reduced. On the contrary, when the diameter of the HDPE or nylon is less than 0.8 mm, 0.4 mm respectively, easy to bend with fixed pattern curve effect is reduced. Therefore, the HDPE, nylon filament threads are formed within a proper diameter range is required to keep a fixed pattern curve constant.

As shown in FIG. 4, a plan view of the MWK 11 of the present invention is illustrated, and it is also a top plan view of the MWK 11 of FIG. 3. According to the embodiment as discussed above, for example, after being extended across and downward, each warp 11 a over each weft 11 b are kept distances from one another respectively. Breathable orifices are therefore formed between two adjacent warps and two adjacent wefts respectively. Such an orifice is dimensioned by a distance D4 approaches to 1.0˜2.0 mm between two adjacent warps, and a distance D5 approaches to 0.5˜1.5 mm between two adjacent wefts. Because each warp and weft crosscut but not link together to tie a knot etc., therefore, breathable orifices dimensioned, for example, within a length D4 and a width D5 are formed in between. Therefore, the MWK 11 is bestowed with a proper flexibility in the ensemble.

As shown in FIG. 5, a sectional view of FIG. 4 indicated by numerals 5-5, wherein a weft 11 b (nylon filament thread) is extended across a plurality of warps 11 a (HDPE) in an extended S shape. A center parting distance D1 between two adjacent warps 11 a is determined by a distance D4 between two adjacent warps 11 a divided into two parts. And, a breadth D3 of the MWK 11 is in the range of 1.0˜2.0 mm, a preferable range is 1.3˜1.7 mm.

As shown in FIG. 6, a sectional view of FIG. 4 indicated by numerals 6-6, wherein an HDPE filament thread 11 a is extended across a plurality of wefts 11 b (nylon filament thread) in an extended S shape. A center parting distance D2 between two adjacent wefts 11 b is determined by a distance D5 between two adjacent wefts 11 b divided into two parts. And, a breadth D3 of the MWK is in the range of 1.0˜2.0 mm, preferable 1.3˜1.7 mm.

As shown in FIG. 7, a cross sectional view of the visor with a hemline added to the periphery of the MWK is illustrated. Both warps 11 a and wefts 11 b along the periphery of MWK 11 are trimmed off and a plurality of protruded struts left, not only makes the periphery of MWK 11 not well-balanced, but also warps 11 are separated from wefts 11 b divided into two directions. To avoid such defects from happening, the outer periphery of the cloth material is fringed with a U shape hemline 13, which is further stitched together with MWK 11 and cloth 12 by a stitch 131. The periphery of MWK 11 is reinforced to overcome said defects as mentioned above. Said hemline 13 is made of cloth material or film etc.

As shown in FIG. 8, a sectional view of a periphery of MWK clad in a hemline is illustrated. A sectional view across numerals 9-9 indicated in FIG. 8 is illustrated in FIG. 9. A periphery of MWK 11 clad in a U shape hemline 14, and then stitched together MWK 11 by a stitch 141. The hemline 14 is made of cloth or film. Or a gel (not shown) can be dispersed or injected in between to stick the hemline with the periphery of MWK 11 to form a string of beads like hemline.

As shown in FIGS. 10-12, schematic views of the visor of the present invention in applications are illustrated. In FIG. 10, the visor 1 is bent downward from both sides of the front border. Or as depicted in FIG. 11, the visor is bent upward from the central portion. Or as depicted in FIG. 12, the central portion of the visor is bent upward. Because the fixed pattern curve of the visor can be shaped at will, there are exemplified only for the user's reference.

Advantage Obtained By the Application of the Present Invention

The benefits and advantages can be achieved by the present invention as following:

Each of HDPE filament threads is extended across and downward each of nylon filament threads can reduce the capital expenditure likely devoted to a whole HDPE sheet; thereby the material cost can be lowered.

When a multiaxial warp knit fabric is formed by warp knitting, “capillaryity” may be induced between each being extended across weft and warp, due to both of HDPE and nylon filament threads are prefabricated with an extended S waves to cross cut one another intermittently and reciprocally, but not to tie a knot further integrally interwoven or interlaced as a whole sheet, thereby a MWK is not closely knit, which is more permeable and breathable than the prior arts (such as US 2006/0143793) or conventional sheet.

Because at least the nature of a warp, a HDPE filament thread is relatively attributed to a flexibly easy to bend thread, while the nature of a weft, a nylon filament thread, Thus a warp (HDPE) is extended across and downward a weft (nylon) respectively is possible to form a flexible grid like template MWK neither too hard nor too soft. Thereby a visor is easy to bend with a fixed pattern kept constant in the ensemble unless the user bends the visor by such as his fingertip force to transform the already shaped pattern curve of the visor. 

1. A visor with fixed patterns curve comprising a visor combined to a crown to form a cap, characterized in that: the visor consists of a multiaxial warp knit fabric (MWK) clad in a cloth, MWK is formed by each of a plurality of warps is extended across and downward each of a plurality of wefts respectively, a high density polyethyelene (HDPE) filament thread as a warp is flexibly easy to bend with a fixed pattern curve, a nylon filament thread as a weft is pliably and toughly extendable, distances kept between adjacent wefts and warps to form breathable orifices.
 2. A visor with fixed pattern curve according to claim 1 wherein a diameter of the HDPE filament thread is 0.8˜1.8 mm.
 3. A visor with fixed pattern curve according to claim 1 wherein a diameter of the HDPE filament thread is 1.1˜1.5 mm.
 4. A visor with fixed pattern curve according to claim 1 wherein a diameter of the extendable nylon filament thread is 0.4˜1.2 mm.
 5. A visor with fixed pattern curve according to claim 1 wherein a diameter of the extendable nylon filament thread is 0.6˜0.8 mm.
 6. A visor with fixed pattern curve according to claim 1 wherein a breadth of MWK is 1.0˜2.0 mm.
 7. A visor with fixed pattern curve according to claim 1 wherein a breadth of MWK is 1.3˜1.7 mm.
 8. A visor with fixed pattern curve according to claim 1 wherein a distance between the warp and the weft is 1.0˜2.0 mm.
 9. A visor with fixed pattern curve according to claim 1 wherein a periphery of the cloth is pressed from both sides by a “U” shape hemline, which is stitched together with the cloth, and MWK by a stitch.
 10. A visor with fixed pattern curve according to claim 1 wherein a periphery of MWK is enclosed by a “U” shape hemline, and stitched by a stitch or adhered by a gel to fix to MWK.
 11. A visor with fixed pattern curve according to claim 1 wherein a HDPE filament thread bent curve at a degree in the range from 20˜180 degrees.
 12. A visor with fixed pattern curve according to claim 1 wherein a nylon filament thread extendable with a degree, after bending, above 50˜60 degrees. 